Wall supporting structural beam



P 1966 L. R. DOWNING, JR 3,271,920

WALL SUPPORTING STRUCTURAL BEAM 2 Sheets-Sheet 1 Original Filed Sept. 7, 1962 INVENTOR. LLJC/EN Q. DOWN/N6 J12.

TlE E ATTOQNEYE.

Sept. 13, 1966 DQWNING, JR 3,271,920

WALL SUPPORTING STRUCTURAL BEAM 2 SheetsSheet 2 Original Filed Sept.

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4 TTOQNEYS United States Patent 3,271,920 WALL SUPPORTING STRUCTURAL BEAM Lucien R. Downing, Jr., Avon Lake, Ohio, assignor to Donn Products, Inc., Westlake, Ohio, a corporation of Ohio Original application Sept. 7, 1962, Ser. No. 221,988, now Patent No. 3,217,460, dated Nov. 16, 1965. Divided and this application Apr. 21, 1965, Ser. No. 458,506 4 Claims. (Cl. 52735) This application is a division of my coapending application Serial No. 221,988 filed September 7, 1962, now Patent No. 3,217,460 dated November 16, 1965.

This invention relates, as indicated, to a structural beam especially adapted for use as a supporting member in a double-wall construction, and to a double wall construction including the same.

Patent No. 2,931,470 to Donald A. Brown discloses certain improved hollow metal studs having a configuration which enables them to receive and retain conventional fastening means such as nails or screws, whereby panel members may be secured thereto on either side to form a double-wall structure. Introduction of so-cal-led nailable metal studs has facilitated the installation of room dividing partition members or walls.

The present invention is an improvement on the wall structures heretofore fabricated with metal beams or studs. With the beam or stud structures of the present invention, improved assembly of double wall structures may be obtained together with considerable economy in their use over that experienced with prior metal stud structures.

Other objects of the invention will appear as the description proceeds.

To the accomplishment of the foregoing and related ends, said invention, then, consists of the means hereinafter fully described and particularly pointed out in the appended claims, the following description and annexed drawings setting forth in detail certain illustrative embodiments of the invention, such disclosed means constituting, however, but a few of the various forms in which the principle of this invention may be employed.

In the annexed drawings:

FIG. 1 is a fragmentary perspective view of a metal stud of the present invention;

FIG. 2 is a fragmentary perspective view of another form of metal stud of the present invention;

FIG. 3 is a fragmentary cross-sectional view through a typical double-wall section including a metal stud such as shown in FIG. 1 and showing the relationship of opposed wall-forming panel members with respect thereto;

FIG. 4 is a fragmentary cross-sectional view showing one mode of providing for an opening, e.g., a doorway, through a double-wall construction in accordance herewith; and l FIGS. 5, 6 and 7 show in diagrammatic cross-section a portion of a double-wall including stud members such as shown in FIG. 1, in various stages of construction.

FIG. 8 is a crosssectional view of another form of metal stud in accordance herewith.

Briefly stated, the present invention is in the provision of a beam for structurally supporting a pair of panel members in a common plane in edge-to-edge relation to each other, and in fixed spaced parallel relation to an opposite panel member to form a double wall structure. The beams of the present invention include a web portion, which is adapted to be disposed in a plane normal to the panel surfaces. Along one marginal edge of the web portion, there is a laterally eXtending flange which is adapted to be disposed in parallel contiguous relation with a surface of the panel member which is opposite to the pair of panel members in edge-to-edge relation.

This flange is adapted to receive a panel fastening member, e.g., a self-threading screw or a nail, therethrough for interlocking the panel with the flange. The remaining marginal edge of the main web is displaced laterally to form an auxiliary web integrally connected with the main web by a transverse portion forming a lateral abutment surface for the marginal surface of one of the pair of panel members. A second lateral abutment surface for the marginal surface of the other of the pair of panel members is provided also on said auxiliary web. The auxiliary web, then, is adapted to be disposed between the mating edges of the pair of panel members, and contains also means coacting with the auxiliary web in spaced relation from the lateral abutment surfaces for engaging and retaining the pair of panel members in fixed abutting relation thereagainst.

In a preferred embodiment, the main web portion of the beam includes spaced perforations of suflicient size to permit the passage of service lines through the beam.

Referring now more particularly to FIG. 1, there is here shown in fragmentary perspective, a beam or stud member formed from thin section metal, e.g., cold rolled steel .020" thick. There is provided a main web portion 10 defining spaced parallel marginal edges 11 and 12. Along marginal edge 11 there is provided a laterally extending flange 13 which, as shown in FIG. 3, is adapted to be disposed in contiguous relation with a surface of a panel member, and to receive a panel fastening member in interlocking relation therethrough. In order to improve the rigidity of the beam and particularly the flange 13, there is conveniently provided -a lip 14 coextensive in length with the flange 13 and lying in a plane which is parallel to the plane of the web 10. In the preferred embodiment, the plane of the flange 13 is normal to the planes of the web 10 and the lip 14.

As shown in FIG. 1, the web 10 is provided with a plurality of spaced openings 15 which are especially useful for passing service lines through the beams, such as electric wire containing conduit, water lines, gas lines, and the like.

Along marginal edge 12 of web 10 there is provided a flange structure which is different from the structure of flange 13 and operates in a manner differently therefrom. As shown in FIG. 1, the web 10 has been displaced out of the plane of the web 10 to form an auxiliary web 16 which is interconnected with the main web 10 by a transverse portion 17 which forms a lateral abutment surface against which the marginal surface of one of a pair of panel members may be pressed. Auxiliary web 16 also defines a pair of parallel spaced marginal edges 18 and 19. In order to provide a lateral abutment surface for the marginal surface of the other of the pair of panel members, means are provided along the marginal edge 18, such as tabs 20 which are struck from the web 16 and adapted to lie in the plane of transverse portion 17. Transverse portion or lateral abutment 17 and tab 20 coa-ct with the marginal surfaces of adjacent abutting panel members in end-to-end relation to restrain motion of the panels in a direction toward the flange 13.

In order to restrain motion of such panels in a direction away from the flange 13, means are provided along the marginal edge 19 of auxiliary web 16 for engaging and retaining the pair of panel members in fixed abutting relation against transverse portion 17 and tab 20. In the embodiment shown in FIG. 1, these means include a lip- 21 coextensive in length with the auxiliary web 16 bent out of the plane of the auxiliary web 16 and into a plane parallel to and spaced from transverse portion 17. For coact-ion with the adjacent panel member, clamping .tabs 22 are struck from the web 16 in a direction away from lip 21 and in the same plane as lip 21. A suitable spacing for clamping tabs 22 and abutment tabs is 6" on center, and the tabs may have a length axially of the beam of from .75" to 1".

The mode of operation of a beam such as shown in FIG. 1 may be better understood by having reference to FIG. 3, wherein there are shown a pair of panel members and 31 in edge-to-edge relation and lying in a common plane. An opposite panel member 33, which is not discontinuous in the region of stud 32, is shown in spaced parallel relation to panels 30 and 31. The combination of panels 3031 with panel 33 forms a double wall section, as partially shown in FIG. 3. Similar numbers to indicate similar parts have been placed on the beam shown in FIG. 3 for comparison with FIG. 1. It will be seen that the auxiliary web 16 is disposed between the mating edges of the panels 30 and 31, which are in edge-to-edge relation. Transverse portion 17 receives in abutting relation therewith the marginal surface 36 of panel 30. The marginal surface 36 is held in abutting relation with transverse portion 17 by the clamping eiiect of lip 21 engaging the slightly recessed outer marginal surface 37 of panel 30. In like manner, the inner marginal surface 38 of panel 31 is in abutting relation with laterally extending tab 20, being held in such relation through the action of clamping tab 22 which engages outer recessed surface 39 of panel 31.

Provision of recesses 37 and 39, for example, along the marginal edges of panel members such as plasterboard, or the like is conventional so that a tape 40 may be applied over the junction of the adjacent panel boards 39 and 31, for example, and the tape subsequently obliterated by the application of a thin coat of plaster thereover. When treated in this manner, it will be observed tha-t lip 21, web 16 land clamping tabs 22 are completely obliterated from view.

Along the opposite marginal edge of web 10, laterally extending flange 13 is shown in parallel contiguous relation with panel 33 which, as will be hereinafter more particularly explained, is continuous in the region of beam 32. Fastening means such as selfthreading screw 41 :are shown in position for fastening panel 33 in interlocking relation with stud 32.

FIG. 2 shows another form of stud or beam in accordance with the present invention, there being here shown in perspective fragmentary view a beam having a main web portion and la laterally extending flange portion 51, which in turn is provided with an upstanding lip portion 52. As with the beam shown in FIG. 1, a portion of the web is displaced out of the plane of the web St) to form an auxiliary web 53 integrally interconnected with the main web 50 by a transverse portion 54 which forms a lateral abutment surface for the marginal surface of one of the pair of panel members, for example, panel 30 in FIG. 3. By reversely folding the metal and providing an offset portion, means are provided on the auxiliary web for forming an opposing lateral abutment surface 55 which is adapted to be maintained in contact with the marginal surf-ace of the other of the pair of panel members, e.g., panel 31 in FIG. 3. As with the device shown in FIG. 1, auxiliary web portion 53 is adapted to be disposed between the mating edges of the pair of panels, e.g., panels 30 and 31 of FIG. 3. In this case, the means coacting with the auxiliary web for engaging and retaining the pair of panel members in fixed abutting relation against the [abutment surfaces comprise a plurality of edge engaging points, e.g., points 56, 57 land 58, which are struck outwardly from the auxiliary web 53 in opposite directions, and lie in planes which are parallel to the plane of the abutment surfaces 54 and 55, respectively. The points 56, 57 and 58, for example, are adapted to be driven into the confronting edges of the mating panels, e.g., panels 311 and 31, to retain the panel members in fixed abutting relation against the abutment surfaces 54 and 55, as above mentioned.

In use, the stud member shown in FIG. 2 has the advantage that less metal is exposed to the plaster surface at the juncture of the confronting edges of panels 30 and 31, the only exposed metal being the marginal edge of auxiliary web 53. The web 50 is also provided with openings 59 and 60, if desired, for passage of service lines through the studs.

FIGS. 5, 6 and 7 illustrate the manner of assembling a double-wall section utilizing the studs of the present invention. In FIG. 5, then, which is a diagrammatic representation of the first stage of assembly, a channel member has been secured by any suitable means to a wall surface, for example, 71. Coacting channels above and below have also been put into place, FIG. 5 showing the lower channel 72 which is merely a longitudinal member having parallel marginal edges with upturned flanges coextensive in length therewith and having a cross-section such as shown for channel 70. Transverse channels 72 at the floor and at the ceiling extend in the direction which the wall is to ultimately take. The free end of the wall section, such as shown in FIG. 5, may terminate in the door-casing, for example, such as that illustrated in FIG. 4. Intermediate the wall surface 71 and the termination of the double wall section, which may also be another wall surface, stud members having a configuration such as shown in FIGS. 1 or 2 may be inserted at normal stud intervals, e.g., 24" on center. Because of the recessed portion 23, at the extremities of the stud member, such as shown in FIG. 1, the studs may be inserted in the upper and lower channels, e.g., lower channel 72, and merely twisted into position owing to the resiliency of the laterally extending flanges on the channels. As shown in FIGS. 5, 6 and 7, the stud members are disposed in opposite manner, for example, the compound flange portions, generally indicated at 73 and including the auxiliary web, laterally extending abutment surfaces, and laterally extending clamping surfaces are disposed on opposite sides of the channel respectively in alternating fashion. No fastening means are employed to restrain the beams or studs within the channels, they being 'frictionally held thereby. There may then be brought into the position the first panel member 74 which is a standard 4-foot Wide plasterboard. 'Panel 74 rests on the floor adjacent channel 72, the surface of one of its marginal extremities abutting against upright channel 70. Stud member 76 may then be moved into position in interlocking engagement with the vertical marginal edge of panel 74, by sliding stud 76 to the left in channel-way '72 and bringing the material edge of the panel and the compound flange 7-3 into interlocking engagement. Panel 74 is now firmly held in position without any fastening means whatever. In like manner, panel 81 may now be brought into interlocking engagement with the opposite side of compound flange 73 of stud 76, with stud 78 then being moved into position to bring its compound flange 73 into interlocking relationship therewith. Studs and 77 support the central portions of panels 74 and 81, respectively, since the laterally extending flanges thereof [flange 13, FIG. 1] are in contiguous parallel relation with the continuous inner surfaces of panels 74 and 8 1, respectively. Assembly of the wall in this manner is continued by inserting panel 82 and bringing stud 80 into interlocking engagement therewith, stud 79 being adjusted to the central position of panel 82. Frequently, panel member such as panel 82 will contain a score line or the like indicating the center line so that alignment of a stud member such as stud 79 against the plane continuous surface of a panel member '82 is very easily effected. This operation is continued until the studs and one of the wall panel portions is in place. Thereafter, service lines, e.g., electric lines, water lines, gas lines, and the like, may be positioned within the wall by means of threading these units through openings such as opening 15 of FIG. 1.

To complete the wall, the procedure illustrated in FIG. '6 is followed. In this case, instead of a standard 4-foot wide panel member, a 2-foot Wide section 83 is first inserted. Stud member 75, not being anchored to anything, may then be moved .so as to bring its flange portion 78 into interlocking engagement with the short width panel 83. Thereafter, the assembly of the panels 84, 85 and 86, for example, to complete the double-wall structure is identical with the procedure given with respect to FIG. 5. At this point, no fastening means have been employed and economy of time is effected in avoiding changing operations, for example, from emplacement of studs to seating of fastening means and back to emplacement of studs.

FIG. 7 shows a final stage in the construction of a double wall structure, wherein fastening means are seated to secure the studs and panels in place. \A preferred fastening device for plasterboard panels, for example, is a self-threading steel screw which can be seated to hold the panels and flanges, respectively, in tight contiguous relation by means of a pneumatic screwdriver. It will be observed from FIG. 7 that with the exception of the terminal channel members, fastening means are employed on each side of the double-wall at every other stud member, thereby materially reducing the number of fasteners and fastening operations to be performed. It has been calculated that the cost of the fastener and the fastening operation aggregates about three cents per fastener at current rates. Material reduction in the number of fasteners and fastening operations, thereby effects a substantial saving in the cost of the wall structure.

Following the emplacement of the fastening means, the joints between adjacent panels supported in edge-to-edge relation may be taped and plastered to provide a smooth wall surface as is customary.

Referring now to FIG. 8, there is here shown another embodiment of this invention which provides for variations in the thickness of the wall panels to a greater degree than other embodiments. In dry wall materials, for example, considerable variation in panel thickness may be experienced and it is then desirable to utilize a beam structure cross-section such as shown in FIG. 8. Web portion 90 is provided at its lower marginal edge with a laterally extending flange portion 91 which in turn is provided with an upturned lip portion 92. As with the beams shown in FIGS. 1 and 2, a portion of the web 90 is displaced out of the plane of the web 90 to form an auxiliary web 93 which is integrally connected with the main web 90 by transverse portion 94 including bead portion 95 which forms an abutment surface for the marginal surface 95a of one of the pair of panel members 96 and 97. By reversely folding the metal and providing an offset portion 100, means are provided as in FIG. 2, on the auxiliary web 93 including bead portion 98 for forming an opposing lateral abutment surface 98 which is adapted to be maintained in contact with the marginal surface 99 of panel 97 which is shown in place relative to the beam of FIG. 8. Panel 96 is thicker than panel 97 and is shown in position for insertion relative to the stud. It will be observed that as the panel 96 is rotated relative to the stud to alignment in the plane of panel 97, it will fulcrum on bead 95 and effect a separation of the reverse folded portion 100 permitting adjustment in the distance between Tab 101 and abutment 95 to accommodate the thicker panel 96. The distance between Tab 102 and abutment 98 also varies to accommodate variations in panel thickness.

There has thus been provided an improved panel supporting stud or beam which is characterized by a web portion having a flange of one character lalOIlg one marginal edge of the web, and a flange of an entirely different character along the opposite marginal edge of the Web. The first-mentioned flange is adapted to be placed in contiguous parallel relation with a continuous panel surface and to receive fastening means for securing the panel to the flange. The second-mentioned flange means provides a structure for receiving the confronting or mating edges of a pair of panels in adjacent relationship and in a common plane and for retaining the marginal edges of such panels in end-to-end relationship without the necessity for employing fastening means.

Other modes of applying the principle of this invention may be employed instead of those specifically set forth above, changes being made as regards the details herein disclosed provided the elements set forth in any of the following claims, or the equivalent of such be employed.

It is, therefore, particularly pointed out and distinctly claimed as the invention:

1. A beam for structurally supporting a pair of panel members of disparate thickness in a common plane in edge-to-edge relation to each other and in fixed spaced parallel relation to an opposite panel member to form a double-wall structure, comprising a main web portion disposed in a plane normal to the panel surfaces, laterally extending flange means along one marginal edge of said web portion disposed in parallel continuous relation with a surface of said opposite panel member for receiving a panel-fastening member in interlocking relation therethrough, the other marginal edge of said main web being displaced laterally to form an auxiliary web integrally interconnected with the main web by a transverse portion, said transverse portion comprising a first part extending away from said main web and a second part rebent above said first part toward said main web, said auxiliary web extending parallel to said main web substantially intermediate said first part from the marginal edge of said second part, said first part forming a lateral abutment surface for the marginal surface of one of said pair of panel members, said second rebent part forming an opposing lateral abutment surface for the marginal surface of the other of said pair of panel members, said auxiliary web being disposed between the mating edges of said pair of panel members, and means coacting with said auxiliary web in spaced relation from said lateral abutment surfaces for engaging and retaining said pair of panel members in fixed abutting relation thereagainst.

2. A beam in accordance with claim 1, wherein engaging and retaining means includes a plurality of oppositely directed tabs projecting from the plane of the auxiliary web and lying in a plane which is substantially parallel to the abutment surfaces.

3. A beam in accordance with claim 2 wherein the projecting tabs are disposed on the free marginal edge of the auxilary web.

4. A beam in accordance with claim 3 wherein the abutment surfaces include a pair of parallel continuous beads.

References Cited by the Examiner UNITED STATES PATENTS 2,316,668 4/ 1943 Bronner 52-481 2,821,274- 1/ 1958 Olsen 52-48 1 FRANK L. ABBOTT, Primary Examiner.

RICHARD W. COOKE, 111., Examiner.

R. S. VERMUT, Assistant Examiner, 

1. A BEAM FOR STRUCTURALLY SUPPORTING A PAIR OF PANEL MEMBERS OF DISPARATE THICKNESS IN A COMMON PLANE IN EDGE-TO-EDGE RELATION TO EACH OTHER AND IN FIXED SPACED PARALLEL RELATION TO AN OPPOSITE PANEL MEMBER TO FORM A DOUBLE-WALL STRUCTURE, COMPRISING A MAIN WEB PORTION DISPOSED IN A PLANE NORMAL TO THE PANEL SURFACES, LATERALLY EXTENDING FLANGE MEANS ALONG ONE MARGINAL EDGE OF SAID WEB PORTION DISPOSED IN PARALLEL CONTINUOUS RELATION WITH A SURFACE OF SAID OPPOSITE PANEL MEMBER FOR RECEIVING A PANEL -FASTENING MEMBER IN INTERLOCKING RELATION THERETHROUGH, THE OTHER MARGINAL EDGE OF SAID MAIN WEB BEING DISPLACED LATERALLY TO FORM AN AUXILIARY WEB INTEGRALLY INTERCONNECTED WITH THE MAIN WEB BY A TRANSVERSE PORTION, SAID TRANSVERSE PORTION COMPRISING A FIRST PART EXTENDING AWAY FROM SAID MAIN WEB AND A SECOND PART REBENT ABOVE SAID FIRST PART TOWARD SAID MAIN WEB, SAID AUXILIARY WEB EXTENDING PARALLEL TO SAID MAIN WEB SUBSTANTIALLY INTERMEDIATE SAID FIRST PART FROM THE MARGINAL EDGE OF SAID SECOND PART, SAID FRIST PART FORMING A LATERAL ABUTMENT SURFACE FOR THE MARGINAL SURFACE OF ONE OF SAID PAIR OF PANEL MEMBERS, SAID SECOND REBENT PART FORMING AN OPPOSING LATERAL ABUTMENT SURFACE FOR THE MARGINAL SURFACE OF THE OTHER OF SAID PAIR OF PANEL MEMBERS, SAID AUXILIARY WEB BEING DISPOSED BETWEEN THE MATING EDGES OF SAID PAIR OF PANEL MEMBERS, AND MEANS COACTING WITH SAID AUXILIARY WEB IN SPACED RELATION FROM SAID LATERAL ABUTMENT SURFACES FOR ENGAGING AND RETAINING SAID PAIR OF PANEL MEMEBRS IN FIXED ABUTTING RELATION THEREAGAINST. 